System and method for producing beads

Abstract

The present invention relates to a method for producing beads comprising a material capable of gelation, said method comprising the steps of: (i) combining (a) a liquid composition comprising a material capable of gelation; and (b) a first hydrophobic phase; (ii) subjecting the liquid composition and the first hydrophobic phase, to means for emulsification in a first reactor by addition of external mechanical energy creating an emulsion comprising individual droplets comprising the material capable of gelation in the first hydrophobic phase (wherein the material capable of gelation provides a discontinuous phase and the first hydrophobic phase provides a continuous phase); (iii) stabilizing the droplets by transferring the emulsion from the first reactor to a stabilization reactor wherein the emulsion obtained in step (ii) is subjected to means for gelation in order to obtain gelation within 5 minutes or less, and the beads are formed.

The invention claimed is: 
     
       1. A system for producing high density beads having a density of 1.5 q/mL or more and comprising a density controlling core particle surrounded by a material capable of gelation in a continuous method, comprising:
 a) a first reactor, the first reactor comprising:
 i) a liquid inlet for adding to the first reactor a liquid composition comprising a density controlling core particle and a material capable of gelation and a first hydrophobic phase; 
 ii) a mechanical mixer for addition of external mechanical energy input to the liquid composition in the first reactor; 
 wherein the liquid composition comprising the density controlling core particle and material capable of gelation and the first hydrophobic phase are emulsified by addition of external mechanical energy input to the liquid composition to create an emulsion comprising individual high density droplets comprising the density controlling core particle surrounded by the material capable of gelation in the first hydrophobic phase, wherein the density controlling core particle surrounded by the material capable of gelation provides a discontinuous phase and the first hydrophobic phase provides a continuous phase; 
 wherein the emulsion is maintained at a temperature above the gelation point of the material capable of gelation; and 
 iii) at least one liquid outlet, the outlet for transferring the emulsion from the first reactor to a stabilization reactor; and 
 
 b) a stabilization reactor comprising a connection pipe for transferring the emulsion from the liquid outlet of the first reactor, wherein the stabilization reactor subjects the emulsion comprising the density controlling core particle surrounded by the material capable of gelation to gelation conditions by reducing the temperature of the emulsion to a temperature below the gelation point of the material capable of gelation within one second or less after receiving the external mechanical energy input in the first reactor, thereby forming the beads. 
 
     
     
       2. A system according to  claim 1 , further comprising: c) a beads isolation reactor, wherein said beads isolation reactor is connected to the stabilization reactor wherein said beads isolation reactor further comprises an outlet for the removal of beads from the beads isolation reactor. 
     
     
       3. A system according to  claim 1 , further comprising d) a first tank for holding the liquid composition, wherein the first tank comprises a connection to the inlet of the first reactor; and e) a second tank for holding the first hydrophobic phase, wherein the second tank comprises a connection to the inlet of the first reactor. 
     
     
       4. A system according to  claim 1 , further comprising d) a first tank for holding the liquid composition, wherein the first tank comprises a connection to the inlet of the first reactor; and e) a second tank for holding the first hydrophobic phase, wherein the second tank comprises a connection to the inlet of the first reactor. 
     
     
       5. A system according to  claim 3 , wherein the system comprises at least one heater for maintaining (i) the liquid composition comprising the density controlling particle and the material capable of gelation at a temperature above the melting point of the material capable of gelation, or (ii) the first hydrophobic phase at a temperature above the melting point of the material capable of gelation, or (iii) both the liquid composition comprising a material capable of gelation and the first hydrophobic phase at a temperature above the melting point of the material capable of gelation. 
     
     
       6. A system according to  claim 4 , wherein the system comprises at least one heater for maintaining (i) the liquid composition comprising the density controlling particle and the material capable of gelation at a temperature above the melting point of the material capable of gelation, or (ii) the first hydrophobic phase at a temperature above the melting point of the material capable of gelation, or (iii) both the liquid composition comprising a material capable of gelation and the first hydrophobic phase at a temperature above the melting point of the material capable of gelation. 
     
     
       7. A system according to  claim 6 , further comprising f) a heat exchanger comprising an inlet and an outlet interposed between the first and second holding tanks and the first reactor, thereby heating or keeping the temperature of the liquid composition comprising the density controlling core particle and the material capable of gelation at a temperature above the melting point of the material capable of gelation; g) a first pump for transferring the liquid composition from the first tank to the inlet of a heat exchanger; and h) a second pump for transferring the first hydrophobic phase from the second tank to the inlet of the heat exchanger. 
     
     
       8. A system according to  claim 3 , further comprising f) a heat exchanger comprising an inlet and an outlet interposed between the first and second holding tanks and the first reactor, thereby heating or keeping the temperature of the liquid composition comprising the density controlling core particle and the material capable of gelation at a temperature above the melting point of the material capable of gelation; g) a first pump for transferring the liquid composition from the first tank to the inlet of a heat exchanger; and h) a second pump for transferring the first hydrophobic phase from the second tank to the inlet of the heat exchanger. 
     
     
       9. A system according to  claim 7 , wherein the stabilisation reactor further comprises a second hydrophobic phase, wherein the temperature of the second hydrophobic phase is cooler than the temperature of the emulsion, thereby forming a second mixture, wherein said second mixture produces beads. 
     
     
       10. A system according to  claim 8 , wherein the stabilisation reactor further comprises a second hydrophobic phase, wherein the temperature of the second hydrophobic phase is cooler than the temperature of the emulsion, thereby forming a second mixture, wherein said second mixture produces beads. 
     
     
       11. A system according to  claim 1 , wherein the mechanical mixer provides the external mechanical energy input of at least 100 Watt/L of reactor volume. 
     
     
       12. A system according to  claim 1 , wherein the mechanical mixer provides the external mechanical energy input of at least 250 Watt/L of first reactor volume. 
     
     
       13. A system according to  claim 1 , wherein the mechanical mixer provides the external mechanical energy of at least 1,000 Watt/L of first reactor volume. 
     
     
       14. A system according to  claim 1 , wherein the mechanical mixer provides the external mechanical energy of at least 2,000 Watt/L of first reactor volume. 
     
     
       15. A system according to  claim 1 , wherein the mechanical mixer is operated at a speed of 100 rpm or more. 
     
     
       16. A system according to  claim 1 , wherein the mechanical mixer is operated at a speed of 200 rpm or more. 
     
     
       17. A system according to  claim 1 , wherein the mechanical mixer is operated at a speed of 500 rpm or more. 
     
     
       18. A system according to  claim 1 , wherein said mechanical mixer is operated at a speed of 1,000 rpm or more. 
     
     
       19. A system according to  claim 1 , wherein the mechanical mixer is operated at a speed of 3,000 rpm or more. 
     
     
       20. A system according to  claim 1 , wherein the mechanical mixer is operated at a speed of 6,000 rpm or more.